Martin Yale 1601 User manual

R
MODEL 1601
AUTOFOLDER
Specifications
Functional
Paper Weight . . . . . . .16# to 28# Bond Stock (60g-105g)
Form Width . . . . . . . . . . . . . . . . . . .3.5” min. to 8.5” max.
Form Length . . . . . . . . . . . . . . . . . . . .5” min. to 14” max.
Feed Table Capacity . . . . . . . . . . . . . .150 Sheets of 20#
Speed . . . . . . . . . . . . . .9000 sheets per hour (8.5” X 11”)
Fold Styles . . . . . . . . . . . .Letter, Half, Z, Double Parallel,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .and Brochure
Stapled Documents. . . . .Four 24# sheets max, hand fed
Physical
Dimensions . . . . . . . .20.6”Wide X 14.2”Deep X 17.2”High
Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . .38 lbs.
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . . .43 lbs.
Electrical
Power . . .115 V.A.C., 1.3 Amp, Thermal Overload Protected
Table of Contents
1.0 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.2 Feed Table . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.3 Paper Guide Adjustment. . . . . . . . . . . . . . . . Page 3
2.4 Setting Fold Styles . . . . . . . . . . . . . . . . . . . . Page 3
2.5 Exit Ramp Set-up. . . . . . . . . . . . . . . . . . . . . Page 4
2.6 Stacking Wheel Set-up . . . . . . . . . . . . . . . . . Page 4
3.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
3.1 Automatic Feed Operation . . . . . . . . . . . . . . Page 5
3.2 Manual Feed Operation of Multiple Sets. . . . . . Page 5
3.3 Folding Stapled Multiple Sets. . . . . . . . . . . . . . . Page 5
4.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . Page 6
4.1 Fold Roller Removal and Cleaning . . . . . . . . Page 6
4.2 Clearing Paper Jams . . . . . . . . . . . . . . . . . . Page 7
4.3 Feed Wheel Cleaning. . . . . . . . . . . . . . . . . . Page 7
4.4 Bushings and Folding Rollers . . . . . . . . . . . . Page 7
5.0 Troubleshooting Guide . . . . . . . . . . . . . . . . Page 8
5.1 Machine will not run . . . . . . . . . . . . . . . . . . . Page 8
5.2 Paper will not feed . . . . . . . . . . . . . . . . . . . . Page 8
5.3 Crooked folds. . . . . . . . . . . . . . . . . . . . . . . . Page 8
5.4 Ink smudges on paper . . . . . . . . . . . . . . . . . Page 8
5.5 Wrinkled paper. . . . . . . . . . . . . . . . . . . . . . . Page 8
Introduction
Thank you for selecting the Martin Yale Model 1601 Autofolder. We recommend that you familiar-
ize yourself with the Model 1601 Autofolder by carefully reading these instructions. Thorough
understanding of the information contained within this instruction manual will help to eliminate most
operator-associated errors and ensure years of trouble-free performance.
WARNING! Never connect power to the machine until you are ready to set up and operate
the folder. During set up, operation, and maintenance keep hands, hair, loose clothing, and
jewelry away from all moving parts. Serious bodily injury could result. Service or disas-
sembly of the folder should only be attempted with the power disconnected and locked out.
Serial No.

1.0 Nomenclature
2.0 Installation
2.1 Unpacking
Carefully unpack the Model 1601 letter folder and accessories. Place the Model 1601 on a flat, level surface
where it is to be used. It is necessary to have a clear area at the exit end of the folder to place the exit ramp.
Place all of the packing material back in the shipping box and store the box for any future shipment of the Model
1601. Inspect the Model 1601 and all accessories for shipping damage. If any damage is found, contact the
carrier immediately. Note: Always pick up the Model 1601 by its sides, never attempt to lift it by grasp-
ing the roller cover or tables.
2.2 Feed Table
The Model 1601 is equipped with a two position non-removable feed
table. The Model 1601 comes packaged with the feed table in the
down position for shipment and storage. Before the Model 1601 is
used, the feed table will need to be tilted up into the operating position.
Grasp the rear edge of the feed table and pull up (Fig. 3). The feed
table legs will automatically swing down into position. Lock the feed
table into place by insuring the leg shoulder nut slips securely into the
slot in the feed table leg (Fig. 4). To put the feed table back down for
shipping purposes, simply pull the feed table legs away from the fold-
er and let the feed table down.
After the feed table is in position, the feed table extension may be
put into place. First locate the feed table extension in the accesso-
ry package. Install by lining its 2 protrusions with the corresponding
slots on the feed table and inserting the protrusions into the slots.
When it is correctly installed in position, it will lay flat on the feed
table (Fig. 5 & 6).
Fig. 1 Entry View Fig. 2 Exit View
1
2
34
5
6
7
8
10
9
11
12
13
1. Feed table
2. Exit ramp
3. Retarder
4. Manual/automatic feed lever
5. Paper pusher
6. Feed wheel
7. Power switch
8. Cycle button
9. First fold table
10. Second fold table
11. Exit conveyor
12. Stacking wheels
13. Top cover
14. Paper support
14
Fig. 3
Fig. 4
(2)
leg shoulder nut

2.3 Paper Guide Adjustment
Note: the folder is factory adjusted for standard 8.5" paper.
The paper guides feature a dual-purpose adjustment; paper width and skew. These are accomplished with
thumbscrews (Fig. 7). Skew adjustment is factory set to be square with the rollers and should not need adjust-
ing. Skew adjustment is only necessary when the paper is not
cut squarely or has irregular edges
To adjust the paper guide width and/or skew, follow these
steps:
1. Loosen both paper guide thumbscrews slightly and slide
the guides outward.
2. Lift the retarder assembly with the single sheet lever (Fig.
14) and slide a single sheet of the desired paper size under
it. While holding the retarder assembly up, nestle the sheet
gently into the rollers until it is in the center of the feed table
and square with the rollers. Lower the retarder assembly to hold the sheet in place.
3. Slide the paper guides up to the edges of the sheet a lock securely in place with the thumbscrews. Leave
a small gap (1/64" or .4mm) along the edges of the sheet and guides as crowded paper will not feed cor-
rectly.
4. If the guides are not parallel with the paper edges, correct by turning the skew adjustment thumbscrew
slightly. Be aware that skew adjustment is best accomplished after setting the fold tables and running the
folder (refer to 3.1).
2.4 Setting Fold Styles
Before attempting to set-up a fold, the operator should familiarize
themselves with the five designated fold style icons provided on
the rulers located on each fold table (Fig. 8). These icons are
arranged in columns on the feed table rulers that represent the
three common paper sizes (Fig. 9).
2.4.1 Moving the fold table paper stops
Fig. 5 Fig. 6
Fig. 7
Align tabs on
the paper sup-
port with the
slots in the
feed table Lower the
paper support
into position
Paper guide knobs
Skew adjust-
ment knob
Letter
Half
Double Parallel
Z
Brochure
Fig. 8
FOLD
AVOID
8 1/2" x 11"
8 1/2" x 14"
METRIC
FOLD
Fig. 9
Rulers - 2nd Fold Table
Inch fold
ruler
Metric fold ruler
Paper stop indica-
tor, Align orange
arrow with desired
fold arrow on fold
ruler
Inch fold
ruler
Rulers - 1st Fold Table (3)

In order to successfully set the fold tables, the operator must know both the size of the paper being folded and
the type of fold desired.
Size of paper - The fold rulers on the Model 1601 are arranged with 3 separate columns for 3 common paper
sizes. In addition, the icons in each column are color coded for clarity. NOTE: LTR=8 1/2 X 11” (Green),
LGL=8 1/2 X 14” (Purple), and A4=210mm X 297mm (Gold). Make sure the proper colored icon is used for
the appropriate paper size.
Fold Style - Using Fig. 8, determine the type of fold
desired and identify its icon on each fold table.
Remember, use the icon that is the correct color for
the paper size used.
Setting fold stops - Loosen the fold stop thumb-
screw on either fold table (Fig. 10). Move the fold
stop until its arrow aligns with the arrow of the
appropriate icon picked in the above step. Repeat
the process for the other fold table.
Special Notes - Please note that the second fold
table is always in the same location for the half fold,
irregardless of the size of paper being folded. Also
note the blanked area in the second fold table ruler.
DO NOT place the 2nd paper stop in the blanked
area of the fold ruler or a paper jam will result.
2.4.2 Custom folds
To make custom folds, simply use the rulers to gauge the fold length measured from the paper stop edge to the
fold. Please note that the ruler located on the left side of each fold table is in inches
whereas the ruler located on the right side of each fold table is in mm.
2.5 Exit ramp set-up
Align the tabs on the exit ramp with the corresponding slots
on the conveyor and drop the exit ramp into place (Fig. 11).
2.6 Stacking wheel set-up
The Model 1601 is equipped with a conveyor table and
stacking wheels for trouble free document stacking . The
stacking wheel assembly offers (3) separate positions for
the stacking wheels (Fig. 12). The stacking wheels must
be in the correct position for the paper type and fold in
order for the paper to stack correctly. Achart with correct
stacking wheel placement for various paper sizes and folds
is included below. To move the stacking wheels, lift up on
the metal stacking wheel holder and slide the stacking
wheels in to the correct position as indicated in the chart.
Please note that the stacking wheels are not spring loaded,
the weight of the stacking wheel holder simply holds it in
place. To determine the correct stacking wheel position for
custom folds, begin with the stacking wheels in position ‘B’
and move them to positions ‘A’or ‘C’ if stacking problems
are encountered.
AVOID
FOLD
Fig. 10
Fold Stop
Thumbscrew
Fold Style
Icon
Fold Stop Arrow,
Align With Desired
Fold Icon
LTR. Sized
Paper Column
Legal Sized
Paper Column A4 Sized Paper
Column
Fig. 11
Align exit ramp
tabs with slots in
conveyor table
and drop into
place
Fig. 12
ABC
Stacking
wheel bracket
(4)
Side View

3.0 Operation
3.1 Automatic Feed Operation
Set up the folder as described in section 2.0 of these instructions.
Turn the power On by depressing the “I” portion of the Off/On power
switch. Square the stack of paper to be folded by using a Martin Yale
Model 400 Jogger or by tapping 2 sides of the paper stack against a
table or other hard object. Now, while holding the red paper pusher
up, place the stack of paper between the paper pusher and the feed
wheel (Fig. 13). The paper stack should now be straight and resting
squarely on the roller cover. Release the paper pusher and let it come
down and rest on the paper edge. Press the cycle button to initiate
folding. The folder will now start running and process the stack of
paper. Continue holding the cycle button down until the folded paper
begins exiting the machine. The folder will automatically turn off when
the paper runs out. After the folder has shut off, the folded paper may
be removed from the exit ramp and conveyor. NOTE: The user may
find it easier to run only a few sheets before running an entire
stack. This way any adjustments can be made before running a large quantity of paper. If hesitation
occurs in the paper feeding, review machine set-up as described in section 2.0 of this manual. Pay particular
attention to paper guide placement. If the edges of the folded paper do not line up, adjust the skew by turning
the skew thumbscrew slightly. Retest with a few sheets and adjust as necessary to square up the fold.
3.2 Manual Feed Operation of Multiple Sets
The Model 1601 is capable of folding single sheets or
sets of sheets up to 4 pages of #24 bond manually (one
at a time). To do so, set up the machine as described
earlier in section 2.0. With one hand, push the manual
feed lever on the top cover to raise the entire retarder
and paper pusher assembly. While holding the lever,
insert the paper all the way under the retarder until it
stops, using the paper guides to keep it square (Fig. 14).
The lever then can be lowered onto the paper. Press the
cycle button and hold until the folded paper exits the
conveyor.
3.3 Folding Stapled Multiple Sets
The Model 1601 is capable of folding stapled sets of
paper up to 4 sheets of #24 bond in the manual method
described in section 3.2. However, a few simple rules
must be followed to prevent jams or roller damage.
Always attach the staple parallel to the fold rollers.
Always feed the stapled set in with the stapled
Fig. 13
Stacking Wheel Placement Chart
Fold Type
Paper Size
8.5" X 11"
Letter
8.5" X 14"
Legal A4
297mm X 210mm
Z-Fold
Letter Fold
Half Fold
Double Parallel Fold
Gate Fold
B
A or B
B
A
B-
B
C
-
B
B
A or B
B
A or B
B
Fig. 14
Push spring loaded
lever away from opera-
tor and insert paper into
the folding rollers
(5)
Push Up Red
Paper Pusher
Only

edge first (Fig. 15). Avoid using loose fitting staples or inserting
them too close to the edge (less than 5/16", 8mm).
4.0 Maintenance
4.1 Fold Roller Removal and Cleaning
During normal operation, the fold rollers will become contami-
nated with paper dust, ink, copy toner and other performance-
inhibiting materials. At some point this will cause problems such
as wrinkling or marking the paper and even miss-folds or paper
jams. At this time, cleaning the rollers will be necessary. Follow
these steps to remove the roller assembly:
1. Disconnect the power cord from the outlet.
2. Remove (6) Phillips pan head screws from each of the side covers. Remove the side covers by
leaning them out at the top and sliding outward at the
bottom. Be careful with the switch wires on the right
cover.
3.
Remove the drive belt by loosening (do not remove) the four
nuts on the motor and sliding the motor to the left. Slip the
belt off the top edge of the large pulley, then the motor pulley.
Do not over tighten the belt tension during re-installation.
4. Remove the four thumbscrews securing the 1st and 2nd upper
fold tables. Move the 2nd fold paper stop out to its longest
position to ease the removal of the 2nd table (Fig. 16).
5. Pull the upper fold tables straight out a few inches to dis-
engage the bearing blocks. The upper tables can then be
lifted out of the way.
6.
Lower the feed table by pulling the feed table legs away from the folder and letting the feed table down. (Fig. 17).
7. Remove the top cover assembly via the four Phillips flat head screws. Be careful not to damage the
exposed paper pusher spring or retarder during handling.
8. Remove (2) Phillips pan head screws from the bearing blocks. Grasp each bearing block at the top edge
and lift it straight up from the machine Fig. 18).
9. Clean the exposed rollers by spraying Martin Yale Roller Cleaner
and Rejuvenator onto a clean cloth and wiping until all contami-
nates are removed. Turn the rollers with the large pulley to get all
the roller surfaces (Fig. 19). Alcohol or a mild soap and water solu-
tion may also be used. Avoid getting cleaning solutions into the
bearing surfaces. If the fold rollers become glazed or shiny, it may
be necessary to return them to a dull luster by using a lightly abra-
sive non-metallic scouring pad. Never use metal pads such as
steel wool or sand paper, as the shavings or grit will damage
the roller and bearing surfaces.
Fig. 15
Always feed the
stapled set in
with the stapled
edge first and
parallel to the
fold rollers
Fig. 16
Fig. 18Fig. 17
Fig. 19
(6)
Lower feed
table before
removing
bearing blocks

10. If needed, apply a single drop of light machine oil to the inside of the roller shafts next to the bearing
block. Avoid over-oiling as it will seep onto the roller surface and transfer to your paper.
Reassemble the folder by reversing steps 1 through 8. Care must be taken when re-installing the right side
cover. Make certain the wires are not pinched in the the cover!
4.2 Clearing Paper Jams
Use the following steps to clear a paper jam:
1. Disconnect power to the folder.
2. Remove the 1st and 2nd upper fold tables as described in section 4.1, step 4.
3. Pull the jammed paper out from any area where it is accessible. The paper may be pulled from either
fold table or exit conveyor
4. If the jam cannot be cleared using the above technique, the fold rollers will need to be removed as
described in section 4.1. Once the fold rollers are removed, clearing the jam is a simple matter of pulling
the paper from the rollers.
4.3 Feed Wheel Cleaning
As with the fold rollers, contamination of the feed wheel will result in poor performance. When feeding becomes
inconsistent, clean only the outer surface of the feed wheel with a clean dry cloth and alcohol or a mild soap
and water solution. Avoid getting cleaning solutions into the bearing surfaces. Do not use Martin Yale Roller
Cleaner and Rejuvenator or other solvent-based cleaner on the feed wheel, as damage to the rubber and
bearing will result. Never lubricate the feed wheel as it is permanently lubricated!
4.4 Bushings and Folding Rollers
After extended heavy use, the folding rollers and the 8 roller bushings may become worn. In this case a
replacement cartridge is available.
(7)

5.0 Troubleshooting
251 Wedcor Avenue
Wabash, Indiana 46992
Phone: [phone] Fax: [phone]
Email: [email protected] Website: www.martinyale.com
R
M-S027101 Made in the U.S.A. Rev. 3 9/14/05
5.1 Machine
will not run
5.2 Paper will
not feed
5.3 Crooked
Folds
5.4 Ink
smudges
on paper
5.5 Wrinkled
paper
Circuit Breaker has
tripped
Dead receptacle
Electrical Malfunction
Paper guides are to tight
Paper stack is not
square
Feed wheel is contami-
nated
Static electricity buildup
Retarder roller has
developed a flat wear
area
Paper has a curl in it
Excessive paper guide
side play
Paper guide skew
adjustment off
Ink not dry
Excessive toner on pho-
tocopied stock
Feed table paper guide
skew adjustment off
Feed table paper guides
too tight
Dirty Rollers
If the folder has jammed while folding, turn it off for about 10 minutes to allow the thermal
breaker to cool and reset. WARNING! Motor will start automatically once it cools.
Always turn machine off to allow cooling so as to avoid automatic starts.
Try folder in known good receptacle.
Have the Model 1601 serviced by a qualified technician. Call Martin Yale customer serv-
ice at (260)-563-0641 if further assistance is needed.
Adjust the paper guides so that the paper slides freely between them. Review section 2.3.
Make sure the paper stack is square with respect to the folding rollers. Paper must enter
the folder squarely to ensure a straight fold.
Clean the feed wheel as outlined in section 4.3. of this manual.
Fan or jog the paper to loosen the stack. Martin Yale Static Eliminator Spray may be used.
Liberally spray over paper edges, feed tables, fold tables, and exit ramp.
Replace retarder
Paper will sometimes develop a curl that makes automatic feeding difficult. This is espe-
cially common in paper just printed from a laser jet printer. Stacking it and placing a large
heavy object such as a large book on it for a couple hours can straighten paper. Another
option is to place the paper on the Model 1601 feed table with the curl down.
Readjust the paper guides to eliminate excessive side play between guides and paper
edges, per section 2.3 of these instructions.
Readjust paper guide skew adjustment as outlined in section 2.3 of these instructions.
Paper must enter the folding rollers straight, or a crooked fold will result.
Allow additional ink drying time before folding. Some inks do not dry, they only set (dry to
the touch). Because of the physical nature of friction feeding, you may notice a mark on
the leading edge of the paper.
Check copy machine
Align the paper guides with the skew adjustment so the paper feeds straight into the fold-
er. Review section 2.3.
Set guides so that sheets slide freely down between the guides without excessive side
play. Review section 2.3.
Dirty rollers can cause wrinkled paper. Clean rollers as described in section 4.1.